Calorex Pro-Pac Series Quick start guide

page 1
SD566252 ISSUE 48
Pro-Pac system
Pro-Pac 30/45/70/90/140M/MY
Owner installation manual (SD566252 issue 51)

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PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

CONTENTS
AIR/WATER HEAT PUMPS.........................................................4
THE HEAT PUMP CYCLE............................................................5
INSTALLATION. ...........................................................................6
1. SITING......................................................................................6
2. AIR FLOW................................................................................7
3. PLUMBING ..............................................................................8
4. DETERMINING WATER FLOW............................................ 10
5.0 ELECTROLYTIC CORROSION IN SWIMMING POOLS.. 11
5.1 ELECTRICAL (MACHINE WIRING AND SUPPLY).......... 12
6.0 REGULAR PLANNED MAINTENANCE ........................... 27
7.0 CONTROLS AND INDICATION LAMPS........................... 28
8.0 HEAT PUMP MALFUNCTION........................................... 30
9.0 DATA SHEETS.................................................................... 33
10.0 INSTALLATION DRAWINGS........................................... 37
11.0 WINTERISATION PROCEDURE..................................... 47
11.1 START UP PROCEDURE AFTER WINTERISATION ..... 47
12.0 WARRANTY CONDITIONS............................................. 48
13.0 REFRIGERATION DIAGRAMS........................................ 49
14.0 MACHINE RECORD LOG................................................ 51
HEALTH AND SAFETY WARNING
As e dehumidifier embodies electrical and rotational equipment, ONLY competent persons
should carry out any work on is type of machine.
(SEE GUARANTEE)
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SD566252 ISSUE 51

AIR/WATER HEAT PUMPS
IMPORTANT NOTE
Danerm Ltd. is an ISO9001:2000 certified company.
All Calorex heat pumps are CE approved.
MODELS PRO-PAC 30/45/70/90/140
The Calorex Pro-Pac range of air/water heat pumps for
swimming pool applications consist of 5 models. Heat pumps
on is manual are designed for heating pool water and
spas wiin e range 7ºC to 40ºC. The titanium water heat
exchangers fitted in ‘PPT’ Pro-Pacs are suitable for fresh and
salt water pools. Units wi e sux M are suitable for outdoor
pools operating in ambient temperatures above 10ºC, units
wi e sux MY are suitable for outdoor pools operating in
ambients -15ºC to 40ºC.
The units are fully packaged and should be sited outside in a
well ventilated area.
Oer features include integral safety devices to protect e
heat pump from internal and external faults. Indicator lamps
indicate operating mode. An adjustable ermostat controls
water temperature and a 6 minute timer is incorporated to
prevent compressor short cycling. A 12 hour delay timer is
incorporated into all machines, which aer a power interruption
or from initial start will prevent e machine compressor(s)
from starting for a 12 hour period. This feature is to protect
e compressors from liquid pumping which can cause internal
compressor damage.
HEALTH AND SAFETY WARNING
This appliance can be used by children from eight years and above and persons wi reduced
physical, sensory or mental capabilities or lack of experience and knowledge if ey have been
given supervision or instruction concerning e use of e appliance in a safe way and understand
e hazards involved. Children should not play wi e appliance. Cleaning and maintenance shall
not be made by children wiout supervision.
Disconnect from e mains supply and wait ree minutes before removing panels and
commencing work on is machine.
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PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

4. THE EXPANSION DEVICE and from ere, now at
normal pressure, it is returned to e evaporator and e
cycle starts again.
Note at during e cooling cycle is process is reversed.
THE HEAT PUMP CYCLE
3. THE CONDENSER where it is surrounded by e pool water.
e heat is given up to e cooler pool water and e now cold
refrigerant returns to its former liquid state but still under high
pressure from e compressor.
This pressure is released by passing e liquid rough –
Coecient of Performance
The eciency of a Heat Pump is usually called its ‘Coecient of
Performance’ – (C.O.P.) which is simply a ratio of heat output to
energy input, bo being expressed in kW. Thus a Heat Pump
absorbing 1 kW of electricity, collecting 4 kW of energy from e air,
and delivering 5 kW of heat to e pool water is said to have a C.O.P.
of 5:1.
Naturally, is ratio will vary according to e temperature of e water
and e ambient air.
1. THE EVAPORATOR collects e heat from e outside
ambient air, pre-heated by e sun. In e Calorex swimming
pool heat pumps, high volumes of outside air are drawn into
e unit by e fan expelled rough e evaporator fins. The
evaporator has liquid refrigerant passing rough it Which is at a
considerably lower temperature an e ambient air. Therefore
e air gives up its heat to e refrigerant which en vaporizes.
This preheated vapour now travels to –
2. THE COMPRESSOR where it is compressed and
upgraded to a much higher temperature. The hot vapour
now enters –
The Calorex Swimming pool heat pump provides ermodynamic
heating by means of a vapour compression cycle, (similar to at
employed in a conventional refrigerator), in addition to acting as an
active solar collector.
HOT GAS
COMPRESSOR
WATER
OUT
CONDENSED
REFRIGERANT
WATER
IN
HIGH PRESSURE SIDE
HEAT
EXCHANGER
EXPANSION
VALVE
COLD LIQUID
REFRIGERANT
LOW PRESSURE SIDE
EVAPORATOR
COOL GAS
AMBIENT AIR
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SD566252 ISSUE 51

INSTALLATION.
1. SITING
NOTE: These units are not recommended for plant room installation.
1. Ensure heat pump on site is as ordered, i.e. model, electrical supply and
factory fitted options.
2. Inspect unit for damage, in particular inspect e evaporator (finned
side) to ensure at it is undamaged. (Minor indentations in e fins do
not affect performance). If severely damaged, endorse delivery note in
presence of e driver and send a recorded delivery letter to transport
company giving details.
3. Protect unit if installation is delayed.
4. Provide a firm level base capable of supporting operational weight of unit;
spread load on timber floor.
5. Ensure water cannot collect under unit - recommend units are installed
on plin 100mm above finished floor level and also to aid condensate
drainage.
6. Allow adequate clearance to service panels on unit; recommend 500mm
minimum (see installation drawings).
7. All Calorex heat pumps are by design as quiet as is practical, however
due consideration should be given to siting in order to fully exploit
is feature, i.e. ensure at e inlet and outlet grilles face away from
occupied premises.
8. Ensure loose debris such as leaves, grass cuttings, etc will not block air
inlet filters or grilles.
9. Consider protection from extreme weaer conditions.
IMPORTANT NOTE
Li e unit into place using a fork li truck, or similar liing device, if liing e unit from
above spreader bars must be used to avoid any pressure on e sides of e unit or
packing materials.
DO NOT PUSH OR DRAG THE UNIT ALONG THE GROUND.
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PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

Due consideration must be given to air flow, ie do not obstruct inlet or
outlet and ensure discharge air cannot recirculate to inlet (see figures
1 and 2)
Grill or apertures MUST comply wi figures (see Table 1)
< 3 m
CANOPY OR OBSTRUCTION
TOO CLOSE
> 3 m
TYPICAL OUTSIDE INSTALLATION
FIGURE 1 FIGURE 2
TYPICAL INSIDE OR PLANT ROOM INSTALLATION
(NOT RECOMMENDED FOR LONG DUCT RUNS).
THE PLANT ROOM IS NOT TO BE USED AS AN
OCCUPIED SPACE.
ADEQUATE
DUCTING
ADEQUATE
DUCTING
PRO-PAC
90/140
PRO-PAC
30/45/70
TABLE 1
MODEL Minimum Free Area m²
Inlet Discharge
Pro-Pac 30 0.59 0.25
Pro-Pac 45 0.98 0.42
Pro-Pac 70 1.19 0.52
Pro-Pac 90 1.731 0.84
Pro-Pac 140 2.138 1.04
2. AIR FLOW
TABLE 1
Required Free Areas to provide air flow to and from heat pumps when
installed on an enclosed area or where required to pass rough a wall
etc.
Free area is e available area rough which air can pass rough a
grille or louvres.
1. Note: If multiple units are installed in an enclosed area en e inlet free
areas required for each unit can be added togeer to form one inlet
aperture.
2. BUT discharge from each unit must be kept separate and must not be
incorporated into one common duct system.
3. 3. If e unit is installed in a plant room, e room should only be
accessible to auorised persons who are aquainted wi e operation of
e equipment and relevant safety precautions.
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SD566252 ISSUE 51

The Calorex pool heat pump must be connected aer e filter in e
return pipe to e pool. If an existing heater is being retained, en e
Calorex should be connected between e filter and e oer heater.
(See Figures 3 & 4).
1. Calorex heat pumps have water inlet/outlet connections as follows:
2. Suitable breakable couplings should be installed local to heat pump.
3. If heat pump installed at lower level an pool water en isolation valves
should be fitted.
4. Drain valve or plug should be fitted to lower pipe to facilitate drain down
in winter period.
5. The condensation from e evaporator fins drains away rough holes in
e base of e unit. If desired, an optional factory fitted driptray wi 1½"
sink fitting can be fitted to allow e condensate to drain via 1½" domestic
waste piping. In is case it is necessary to ensure at e Calorex Heat
Pump is placed on a level plin so at e condensate can run away
wi adequate fall to waste ie ½" per foot minimum. A U trap should also
be incorporated into e pipework.
6. When e pipework installation is complete e pool pump should
be switched on and e system tested for leaks. Also check e filter
gauge to see at ere is not an excessive increase in back pressure. If
everying is en working normally e water circulating system is ready
to use.
7. Water circuit to and from unit to be capable of maintaining wiin specified
limits e rate of flow required by heat pump (see data sheet).
8. All pipework must be adequately supported wi allowance for
expansion/contraction especially wi plastic pipework.
9. It is recommended at when installing water system e last connections
to be made in e system should be e breakable couplings to avoid any
stresses on to e unit connections.
CORRECT DRAINAGE
FOR CONDENSATE ELBOW
'U' TRAP
SUPPLIED BY
CONTRACTOR
ADEQUATE FALL

MODEL Water in/out
connection size MODEL Water in/out connection size
- - Pro-Pac PPT30M/MY 2" UNION SOCKET
Pro-Pac 45 1½ BSPM Pro-Pac PPT45M/MY 2" UNION SOCKET
Pro-Pac 70 1½ BSPM Pro-Pac PPT70M/MY 3" BSPM
Pro-Pac 90 1½ BSPM Pro-Pac PPT90M/MY 3" BSPM
Pro-Pac 140 2" BSPM Pro-Pac PPT140M/MY 4" BSPM
3. PLUMBING
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PR0-PAC SYSTEM OWNER INSTALLATION MANUAL

IMPORTANT
1. All pool purifying devices and chemical injection systems to be fitted
down stream of heat pumps unless installation is as per filter dosing (see
figure 3).
This includes e practice of dosing chemicals direct into skimmer basket,
which results in concentrated corrosive liquids passing over vulnerable metal
components.
2. Water quality must be maintained as follows:
3. Maximum pressure of water in heat pump circuit should not exceed 3 kg/cm² (50 psi).
pH 7.2 - 7.8
Total Alkalinity 80 - 120 ppm as CaCO3
Total Hardness 150 - 250 ppm as CaCO3
Total dissolved solids 1000 Max ppm
Saline Water (Titanium Condenser) 35,000 Max ppm
Saline Water (Cupro Nickel Condenser) 8,000 Max ppm
Chlorine - free Cl Range 1.0 - 2.0 ppm Domestic
Chlorine - free Cl Range 3.0 - 6.0 ppm Commercial
Ozone 0.9 Max ppm
Bromine 2 - 5 ppm
Baquacil 25 - 50 ppm
Aquamatic Ionic Purifier Max 2 ppm Copper
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SD566252 ISSUE 51

POOL WATER SCHEMATIC
FILTER
FLOW SETTING
PRESSURE GAUGES
METHOD
PUMP
POOL
NON
RETURN
VALVE
SANITISER OR
CHEMICAL DOSING
POSITION AFTER
CALOREX
(STANDARD)
CALOREX
ENSURE POOL FILTRATION PUMP SELECTION ALLOWS FOR ALL SYSTEM RESISTANCE
OR LOOP
FLOW
SETTING
FLOW METER
METHOD
VALVE
VALVE
ISOLATING
B
ISOLATING
A
VALVE C
BYPASS VALVE
(LOCKING GATE VALVE TYPE)
AUX
HEATER
IF FITTED
FLOW METER METHOD (SEE FIG 3.)
Ensure isolation valves ‘A’ and ‘B’ and bypass valve ‘C’ are fully open.
Close e bypass valve until e flow light at is positioned on e
heat pump console illuminates and en close it slightly more to allow
for flow loss due to a dirty filter. Remove handle and lock off valve ‘C’.
Alternatively a water flow meter can be installed. See data sheets for
flow rates.
The Pro-Pac is fitted wi a water flow switch which inhibits e
operation of e machine when e minimum water flow is inadequate.
Adjust e water flow rate rough e heat pump until e green
Water Flow OK lamp on e machine console is illuminated. An
adequate water flow rate has now been achieved.
Fig 3
4. DETERMINING WATER FLOW
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PR0-PAC SYSTEM OWNER INSTALLATION MANUAL